Cap shape retainer

ABSTRACT

A cap shape retainer member includes an elongated portion that is interconnectable with the brim of a cap when the brim is in a planar condition. The retainer member is plastically deformable with a single operation to a shape corresponding to the desired curved condition of the brim. When in the desired curved condition, the retainer member resists biasing forces in the brim biasing the brim toward the planar condition.

FIELD OF THE INVENTION

[0001] The invention relates to apparatus for retaining the shape of the brim of a cap.

BACKGROUND

[0002] Typically, caps are manufactured and sold with the brim or bill portion in a substantially straight or planar condition. It is typically up to the wearer of such a cap to form the brim to a desired shape (usually a curved shape).

[0003] Brims are typically constructed of material that is characterized by elasticity that biases the brim toward the planar condition. Thus, when a brim is curved, the brim will tend to spring back to its planar condition. A brim is formed into a curved shape by bending the brim past the brim materials elastic limit, thereby imparting a component of plastic deformation to the brim. Even with the plastic deformation, the brim will usually retain some elasticity, and will spring back to an intermediate condition between the desired curved condition and the planar condition.

[0004] A series of bending procedures is typically required to shape the brim into the desired curved condition. Each bending procedure imparts an incremental amount of plastic deformation to the brim until the brim is plastically deformed into the desired curved condition.

[0005] Alternatively, a brim may be dampened and tied, rubber banded, or otherwise applied to a curved surface (e.g., a softball) mirroring the desired curved condition. The brim may then be left in the applied state until the brim dries. Although some elasticity usually remains in the brim, some degree of curve may be imparted to the brim in this manner.

SUMMARY

[0006] The above-described methods for forming a brim into a desired curved condition usually require a great deal of patience and time. Such labor- and time-intensive methods may cause frustration in the person attempting to form the brim. In some instances, the brim of the cap may be broken if a person tries to obtain a particular form too quickly. This results in a cap having a brim with an unsightly crease in it. Additionally, dampening the brim may cause discoloration of the brim or breakdown of the brim's component materials.

[0007] The present invention provides a shape retainer that is affixed to or formed integrally with the brim of a cap. The retainer is characterized by a relatively low elasticity, such that any deformation of the retainer is substantially entirely plastic deformation. When the retainer is affixed to or formed integrally with the brim of a cap, and deformed into a curved shape corresponding to the desired curved condition of the brim, the retainer has a strength sufficient to resist, substantially entirely, the biasing force of the brim.

[0008] In this regard, a brim provided with a retainer according to the present invention may be formed into the desired curved condition with a single forming step, and the retainer will cause the brim to remain in the desired curved condition despite the biasing force of the brim biasing the brim toward its planar condition.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a front elevational view of a cap having a planar brim.

[0010]FIG. 2 is a side elevational view of the cap of FIG. 1.

[0011]FIG. 3 is a front elevational view of a cap embodying the invention and having a formed brim.

[0012]FIG. 4 is a bottom view of the cap of FIG. 3.

DETAILED DESCRIPTION

[0013] FIGS. 1-4 illustrate a cap 10 (e.g., a baseball cap) including a crown 14, a brim or bill 16 having an undersurface 20, vent apertures 24, and a sweat band 28. The brim 16 of the cap 10 illustrated in FIGS. 1 and 2 is in a generally planar condition. Caps are typically provided from a cap manufacturer in the illustrated planar condition.

[0014] FIGS. 3-4 illustrate the cap 10 having a cap retainer member 32 attached to the undersurface 20 of the brim 16. The retainer member 32 is mounted on the undersurface 20 of the brim 16 with tape, glue, a hook and loop fastener (e.g., Velcro brand), pins, hooks, stitches, or other fasteners. Alternatively, the retainer member 32 may be disposed under the material covering on the brim 16, or integrally formed with the brim 16, so that the retainer member 32 is not seen when in ordinary use. Also, the retainer member 32 may be disposed on the top surface of the brim 16, and attached by any of the above-mentioned means.

[0015] Preferably, the retainer member 32 is continuously interconnected along its entire length to the brim 16. Alternatively, the retainer member 32 may be tacked to the brim 16 at discrete locations along the retainer member's length.

[0016] The retainer member 32 consists of an elongated piece of steel, aluminum, or other metal or alloy having a relatively low elasticity, and that is plastically-deformable. The preferred dimensions for the retainer member 32 are 5½″×¼″×⅛″, but may be altered depending on the size of the brim 16 to which it is applied and the materials used. When the retainer member 16 is plastically deformed, it is characterized by a stiffness resisting deformation from the plastically-deformed state. The brim 16 is formed into the shape shown in FIGS. 3-4 by affixing the retainer member 16 to the undersurface 20 of the brim 16 when the brim 16 is in the planar condition, and bending the brim 16 to the desired curved condition. The retainer member 32 retains the shape provided after only one forming step because substantially all deformation thereof is plastic deformation, and resists the brim's 16 biasing force biasing the brim 16 toward the planar condition shown in FIGS. 1 and 2. Thus, the brim 16 is easily and quickly formed to the desired shape without extensive and labor-intensive effort.

[0017] Alternatively, the retainer member 32 may be made of a plastic material, such as a thermosetting plastic. Such a retainer member 32 may be affixed to the brim 16 as described above, and the brim 16 formed to the desired curved condition. Depending on the plastic material, the retainer member 32 may retain the desired shape without any further steps. For example, the retainer member 32 may include steps that provide a “click” sound to confirm that the brim 16 has been bent an incremental step. Once a step has been “clicked” the retainer member 32 may not be moved back without a pre-determined amount of force.

[0018] Alternatively, the plastic material may be of a type that sets after heat is applied and removed. In that case, heat may be applied to the retainer member 32 while the brim 16 is in the desired shape with a heat source, such as a hair dryer. After the plastic material has been sufficiently heated, and the heat has been removed, the plastic will set and retain a curved shape corresponding to the desired curved condition.

[0019] In another alternative, the retainer member 32 may include first and second pieces, both of which are interconnected to the brim 16 as described above. One of the pieces may include an elongated portion have teeth or holes formed therein. The other piece may include a buckle portion through which the first piece may be fed. The buckle portion may act as a ratchet or detent mechanism to retain the first piece therein at pre-determined increments. If a friction-type buckle is provided, the first piece may be retained in the buckle at any position, and not merely at predetermined increments.

[0020] The retainer member 32 may also be provided in pre-formed curved conditions. In this regard, the brim 16 may be formed around the retainer member 32 prior to affixing the brim 16 to the retainer member 32. Such pre-formed retainer members 32 may be provided with various amounts of curve (e.g., according to radius of curvature) so that a retainer member 32 may be selected corresponding to a particular desired curved condition. A pre-formed retainer member 32 may be made of spring-steel, plastic, fiberglass, any material mentioned above, or any other material that may be provided in a curved condition and that will resist the biasing force of the brim 16.

[0021] The retainer member 32 may be provided in colors complimenting, matching, or contrasting the color of the brim 16. Also, the retainer member 32 may be provided as a clear member, particularly where it is made of plastic or fiberglass. Also, the retainer member 32 may be decorated with the name and logo of a particular sports team, organization, retailer, design, or event. In that case, it is most desirable to position the retainer member 32 on the top surface of the brim 16.

[0022] Although particular embodiments of the present invention have been shown and described, other alternative embodiments will be apparent to those skilled in the art and are within the intended scope of the present invention. Thus, the present invention is to be limited only by the following claims. 

1. A cap comprising: a crown portion; a brim portion bendable between a generally planar condition and a desired curved condition, said brim portion, when in said desired curved condition, having a biasing force biasing said brim toward said planar condition; and a shape retainer member interconnected with said brim, said shape retainer member being plastically deformable to a shape corresponding to said desired curved condition, said shape retainer member substantially entirely resisting said brim biasing force when said retainer member is so plastically deformed; whereby said shape retainer member retains said brim portion in said desired curved condition.
 2. A method for retaining the shape of a brim of a cap comprising the steps of: providing a cap having a brim in a planar condition, the brim having a pre-determined amount of elasticity; providing a retainer member having an elongated portion; interconnecting the retainer member to the brim; bending the brim to a desired curved condition; and resisting with the retainer member a biasing force of the brim that biases the brim toward the planar condition. 